Spiral End Mallet #5: The Mallet Itself--Final Chapter!!!!!!!!!!!!

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Blog entry by Kent Shepherd posted 08-24-2009 10:17 PM 1849 reads 8 times favorited 16 comments Add to Favorites Watch
« Part 4: Banding the Medallion Part 5 of Spiral End Mallet series Part 6: Fine Woodworking Contest »

So, by now you’re asking—Mallet, what mallet? Really, there is a mallet. Amazing, I could spend 4 sessions showing you how to make a little 2” disk. The good news is, that was the Hard Part. I’m assuming if you’re going to actually make this project, you already have a lathe and know how to use it. If you depend on me to teach you to turn, we’re both in trouble. My experience is rather limited in this area.. That said, you’ll see how basic this part really is.

And now Ladies and Gentleman—-The Mallet!
First, glue up your stock, unless you choose to use a solid piece, which is certainly OK. Again, I had Bubinga left over from a job that was 7/8” thick. I ripped it about 3 1/2”, about 6” long or so. These measurments can vary according to the size you want your mallet. The handle was about 12” long which leaves plenty to trim. The handle layout can be anything you choose. Be creative.

Turn the handle to your liking. Leave a tenon about 2” long and 1” in diameter to glue into the head

Use standard procedures for turning the head. Mine is 3” at the large end. Be sure and coordinate the head with the handle so everything flows.

Drill for the medallion before turning. I found when drilling the hole in the end for the handle, it works much better to start with a smaller hole (3/4” works). work your way up through several sizes. I discovered you can’t drill a 2 1/8” hole in the end grain of Bubinga. Obviously, drill the depth of the thickness of your medallion.
My band saw fence worked well for clamping the head for drilling. See it under my projects.

Turn to desired size and shape.

Drill the other end to accept the tenon on the handle. Be carefull turning the tenon to insure a tight fit.

Glue pieces together. You can glue the medallion at the same time.

Clean up everything and finish. I used Watco Danish Oil—3 coats. Follow label directions. Finish off with a coat of paste wax. and YOU ARE DONE

I thank you for taking the time to check out my first blog on how to do something. I know the last part rushed through the steps. I didn’t want to totally bore those of you who know way more about turning than I do. If you need any clarification on any part———just ask.


16 comments so far

View PurpLev's profile


8523 posts in 3070 days

#1 posted 08-24-2009 10:25 PM

fantastic! thanks for the journey!

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View a1Jim's profile


115177 posts in 2998 days

#2 posted 08-24-2009 10:34 PM

Weee doggie that was great. Super job kent thanks for sharing.

-- Custom furniture

View Loucarb's profile


2388 posts in 2866 days

#3 posted 08-24-2009 10:43 PM

Wow that is really nice. I have been trying to get better on my lathe and this would be a great project. Thanks for sharing.

View degoose's profile


7193 posts in 2776 days

#4 posted 08-24-2009 11:13 PM

Kent I really enjoyed reading every word. Unlike my clumsy attempts at blogs yours flowed smoothly and succinctly. Nicely photographed and well set out. I congratulate you but would I expect anything less from a man who uses Bubinga in his jigs?
Thank your from the bottom of my [vast] woodpile.
Larry from the land downunder.

-- Drink twice... and don't bother to cut... @ For lovers of all things timber...

View reggiek's profile


2240 posts in 2691 days

#5 posted 08-24-2009 11:20 PM

That looks too good to use!.....nice job…excellent write up….I was thinking of making a new mallet for my newly acquired set of 2 cherry chisels…..(got em used – guy didn’t want to sharpen them…so he bought a cheap set at HD….I even offered to sharpen them up for him….this helped as I didn’t feel too bad for getting them at a steal).

-- Woodworking.....My small slice of heaven!

View Kent Shepherd's profile

Kent Shepherd

2715 posts in 2707 days

#6 posted 08-24-2009 11:22 PM

Larry, I like that word—-succinctly—-what does it mean????????


View reggiek's profile


2240 posts in 2691 days

#7 posted 08-24-2009 11:27 PM

Hehe…it means in a few words…briefly…abruptly or tersely…..

Just in case you aren’t yanking his chain a bit…hehe

-- Woodworking.....My small slice of heaven!

View Kent Shepherd's profile

Kent Shepherd

2715 posts in 2707 days

#8 posted 08-25-2009 12:14 AM

reggiek, I was but thanks anyway


View mtnwild's profile


3474 posts in 2948 days

#9 posted 08-25-2009 12:45 AM

Well I have not read every word yet, but that is one fine, personalized mallet there! A real craftsman’s tool.

-- mtnwild (Jack), It's not what you see, it's how you see it.

View cabinetmaster's profile


10874 posts in 2979 days

#10 posted 08-25-2009 12:52 AM

Yeppers, Thanks for the blog. Now I must go make me one. You did a fantastic job.

-- Jerry--A man can never have enough tools or clamps

View blackcherry's profile


3292 posts in 3244 days

#11 posted 08-25-2009 02:00 AM

Ken you might want to join the folks over at FWW or Popular Woodworking in writing how to articles. Great writing and illustration on this build, I enjoy the blog and thanks for posting…Blkcherry

View ratchet's profile


1389 posts in 3208 days

#12 posted 08-25-2009 04:57 AM

Very nice explanation of the build. If you don’t like that mallet then you don’t like wood.
Nice work and thanks for sharing.

View Dennis Zongker's profile

Dennis Zongker

2613 posts in 3013 days

#13 posted 08-25-2009 06:53 PM

Great Blog, Kent. Thanks for posting.

-- Dennis Zongker

View Grumpy's profile


21459 posts in 3272 days

#14 posted 08-27-2009 02:55 AM

Well done Kent. Thanks.

-- Grumpy - "Always look on the bright side of life"- Monty Python

View patron's profile


13524 posts in 2762 days

#15 posted 08-31-2009 10:23 PM

kent ,
wonderful mallet ,
and a good blog with the process .
i learned some nice stuff here .
thank you !

and of course when the word BUBINGA ,
appears , larry is sure to follow ,
thats how i get him to look at my projects too (lol )

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

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